U.S. patent application number 13/639592 was filed with the patent office on 2013-06-13 for inductively interrogated passive sensor apparatus.
This patent application is currently assigned to FMC Technologies, Inc.. The applicant listed for this patent is Christopher D. Bartlett, Frank Borke, Corey Jaskolski, John J. Mulholland, Gabriel Silva. Invention is credited to Christopher D. Bartlett, Frank Borke, Corey Jaskolski, John J. Mulholland, Gabriel Silva.
Application Number | 20130147470 13/639592 |
Document ID | / |
Family ID | 44763182 |
Filed Date | 2013-06-13 |
United States Patent
Application |
20130147470 |
Kind Code |
A1 |
Mulholland; John J. ; et
al. |
June 13, 2013 |
INDUCTIVELY INTERROGATED PASSIVE SENSOR APPARATUS
Abstract
A sensor apparatus comprises a first magnetic transducer which
in use is positioned on a first side of a barrier and a second
magnetic transducer which in use is positioned on a second side of
the barrier opposite the first side. The second transducer
comprises a magnetic or electrical property which is dependent upon
a sensible condition on the second side of the barrier, such as the
pressure or temperature on the second side of the barrier. In
operation, the first transducer generates a first magnetic field
which induces the second transducer to generate a second magnetic
field that is dependent upon the magnetic or electrical property of
the second transducer. The first transducer detects the second
magnetic field and generates a signal which is representative of
the sensible condition on the second side of the barrier.
Inventors: |
Mulholland; John J.;
(Dunfermline, GB) ; Jaskolski; Corey; (Severance,
CO) ; Borke; Frank; (Lafayette, CO) ; Silva;
Gabriel; (Kingwood, TX) ; Bartlett; Christopher
D.; (Spring, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Mulholland; John J.
Jaskolski; Corey
Borke; Frank
Silva; Gabriel
Bartlett; Christopher D. |
Dunfermline
Severance
Lafayette
Kingwood
Spring |
CO
CO
TX
TX |
GB
US
US
US
US |
|
|
Assignee: |
FMC Technologies, Inc.
Houston
TX
|
Family ID: |
44763182 |
Appl. No.: |
13/639592 |
Filed: |
April 6, 2010 |
PCT Filed: |
April 6, 2010 |
PCT NO: |
PCT/US10/01045 |
371 Date: |
February 25, 2013 |
Current U.S.
Class: |
324/225 ;
324/234 |
Current CPC
Class: |
G01R 33/0005 20130101;
G01R 33/0017 20130101; G01R 33/02 20130101; G01D 5/204
20130101 |
Class at
Publication: |
324/225 ;
324/234 |
International
Class: |
G01R 33/00 20060101
G01R033/00 |
Claims
1. A sensor apparatus which comprises: a first magnetic transducer
which in use is positioned on a first side of a barrier; and a
second magnetic transducer which in use is positioned on a second
side of the barrier opposite the first side, the second transducer
comprising a magnetic or electrical property which is dependent
upon a sensible condition on the second side of the barrier;
wherein in operation of the sensor apparatus the first transducer
generates a first magnetic field which induces the second
transducer to generate a second magnetic field that is dependent
upon the magnetic or electrical property of the second transducer;
and wherein the first transducer detects the second magnetic field
and in response thereto generates a signal which is representative
of the sensible condition on the second side of the barrier.
2. The sensor apparatus of claim 1, wherein the first transducer
comprises at least one transmitter coil for generating the first
magnetic field and at least one receiver coil for detecting the
second magnetic field.
3. The sensor apparatus of claim 2, wherein the first transducer
comprises two transmitter coils for generating the first magnetic
field.
4. The sensor apparatus of claim 3, wherein each of the transmitter
coils and the receiver coils comprises a toroid.
5. The sensor apparatus of claim 3, wherein the transmitter coils
are positioned coaxially and in parallel planes and the receiver
coil is positioned parallel to the transmitter coils.
6. The sensor apparatus of claim 5, wherein the receiver coil is
positioned between the transmitter coils a distance sufficient to
substantially null out the first magnetic field at the receiver
coil.
7. The sensor apparatus of claim 5, wherein the receiver coil is
positioned between the transmitter coils a distance sufficient to
at least partially null out at the receiver coil a reflected
magnetic field generated by eddy currents in the barrier.
8. The sensor apparatus of claim 1, wherein the first transducer
comprises at least one transmitter coil for generating the first
magnetic field, a first receiver coil for detecting both the second
magnetic field and a reflected magnetic field generated by eddy
currents in the barrier, and a second receiver coil for detecting
primarily the reflected magnetic field.
9. The sensor apparatus of claim 8, wherein the first transducer
comprises two transmitter coils for generating the first magnetic
field.
10. The sensor apparatus of claim 9, wherein the transmitter coils
are positioned coaxially and in parallel planes and the receiver
coils are positioned parallel to the transmitter coils.
11. The sensor apparatus of claim 10, wherein the first receiver
coil is positioned partially between the transmitter coils on one
side of the transmitter coils and the second receiver coil is
positioned partially between the transmitter coils on the
diametrically opposite side of the transmitter coils.
12. The sensor apparatus of claim 11, wherein the second transducer
is positioned opposite the area of overlap between the transmitter
coils and the first receiver coil.
13. The sensor apparatus of claim 8, wherein the first receiver
coil generates a first signal, the second receiver coil generates a
second signal and the sensor apparatus further comprises means for
combining the first and second signals to produce the signal which
is representative of the sensible condition on the second side of
the barrier.
14. The sensor apparatus of claim 2, further comprising a nulling
transducer for generating a third magnetic field which is
sufficient to at least partially null out at the receiver coil a
reflected magnetic field generated by eddy currents in the
barrier.
15. The sensor apparatus of claim 14, wherein the nulling
transducer comprises a coil which is wound around a generally
C-shaped core.
16. The sensor apparatus of claim 15, wherein the C-shaped core is
positioned around a segment of the receiver coil.
17. The sensor apparatus of claim 14, wherein the nulling
transducer comprises a coil which is wound around a toroidal
core.
18. The sensor apparatus of claim 17, wherein the toroidal core is
positioned around a segment of the receiver coil.
19. The sensor apparatus of claim 2, wherein at least one of the
transmitter coil and the receiver coil further comprises a
disc-shaped core which is positioned concentrically therein and is
made of a high permeability material.
20. The sensor apparatus of claim 1, wherein the barrier comprises
a conductive barrier and the first transducer is positioned against
the conductive barrier.
21. The sensor apparatus of claim 1, wherein the barrier comprises
a conductive barrier and the second transducer is positioned
against the conductive barrier.
22. The sensor apparatus of claim 1, wherein the second transducer
comprises a passive sensor device having an electrical property
which is dependent upon the sensible condition on the second side
of the barrier.
23. The sensor apparatus of claim 22, wherein the second transducer
further comprises a coil of conductive wire which is coupled to the
sensor device.
24. The sensor apparatus of claim 23, wherein the sensor device is
electrically connected between the ends of the wire.
25. The sensor apparatus of claim 23, wherein the second transducer
further comprises a magnetically permeable core around which the
wire is wound.
26. The sensor apparatus of claim 25, wherein the core comprises a
relative magnetic permeability of greater than about 1000.
27. The sensor apparatus of claim 1, wherein the second transducer
comprises a coil of conductive wire whose ends are connected
together.
28. The sensor apparatus of claim 27, wherein the second transducer
further comprises a magnetically permeable core around which the
wire is wound.
29. A sensor apparatus which comprises: a first magnetic transducer
which in use is positioned on a first side of a conductive barrier;
and a second magnetic transducer which in use is positioned on a
second side of the barrier opposite the first side, the second
transducer comprising a magnetic or electrical property which is
dependent upon a sensible condition on the second side of the
barrier; wherein in operation of the sensor apparatus the first
transducer generates a first magnetic field which induces the
second transducer to generate a second magnetic field that is
dependent upon the magnetic or electrical property of the second
transducer; and wherein the first transducer detects the second
magnetic field and in response thereto generates a signal which is
representative of the sensible condition on the second side of the
barrier.
30. The sensor apparatus of claim 29, wherein the first transducer
comprises at least one transmitter coil for generating the first
magnetic field and at least one receiver coil for detecting the
second magnetic field.
31. The sensor apparatus of claim 30, wherein the first transducer
comprises two transmitter coils for generating the first magnetic
field.
32. The sensor apparatus of claim 31, wherein each of the
transmitter coils and the receiver coils comprises a torpid.
33. The sensor apparatus of claim 31, wherein the transmitter coils
are positioned coaxially and in parallel planes and the receiver
coil is positioned parallel to the transmitter coils.
34. The sensor apparatus of claim 33, wherein the receiver coil is
positioned between the transmitter coils a distance sufficient to
substantially null out the first magnetic field at the receiver
coil.
35. The sensor apparatus of claim 33, wherein the receiver coil is
positioned between the transmitter coils a distance sufficient to
substantially null out at the receiver coil a reflected magnetic
field generated by eddy currents in the barrier.
36. The sensor apparatus of claim 29, wherein the first transducer
comprises at least one transmitter coil for generating the first
magnetic field, a first receiver coil for detecting both the second
magnetic field and a reflected magnetic field generated by eddy
currents in the barrier, and a second receiver coil for detecting
primarily the reflected magnetic field.
37. The sensor apparatus of claim 36, wherein the first transducer
comprises two transmitter coils for generating the first magnetic
field.
38. The sensor apparatus of claim 37, wherein the transmitter coils
are positioned coaxially and in parallel planes and the receiver
coils are positioned parallel to the transmitter coils.
39. The sensor apparatus of claim 38, wherein the first receiver
coil is positioned partially between the transmitter coils on one
side of the transmitter coils and the second receiver coil is
positioned partially between the transmitter coils on the
diametrically opposite side of the transmitter coils.
40. The sensor apparatus of claim 39, wherein the second transducer
is positioned opposite the area of overlap between the transmitter
coils and the first receiver coil.
41. The sensor apparatus of claim 36, wherein the first receiver
coil generates a first signal, the second receiver coil generates a
second signal and the sensor apparatus further comprises means for
combining the first and second signals to produce the signal which
is representative of the sensible condition on the second side of
the barrier.
42. The sensor apparatus of claim 30, further comprising a nulling
transducer for generating a third magnetic field which is
sufficient to at least partially null out at the receiver coil a
reflected magnetic field generated by eddy currents in the
barrier.
43. The sensor apparatus of claim 42, wherein the nulling
transducer comprises a coil which is wound around a generally
C-shaped core.
44. The sensor apparatus of claim 43, wherein the C-shaped core is
positioned around a segment of the receiver coil.
45. The sensor apparatus of claim 42, wherein the nulling
transducer comprises a coil which is wound around a toroidal
core.
46. The sensor apparatus of claim 45, wherein the toroidal core is
positioned around a segment of the receiver coil.
47. The sensor apparatus of claim 30, wherein at least one of the
transmitter coil and the receiver coil further comprises a
disc-shaped core which is positioned concentrically therein and is
made of a high permeability material.
48. The sensor apparatus of claim 29, wherein the first transducer
is positioned against the conductive barrier.
49. The sensor apparatus of claim 29, wherein the second transducer
is positioned against the conductive barrier.
50. The sensor apparatus of claim 29, wherein the second transducer
comprises a passive sensor device having an electrical property
which is dependent upon the sensible condition on the second side
of the barrier.
51. The sensor apparatus of claim 50, wherein the second transducer
further comprises a coil of conductive wire which is coupled to the
sensor device.
52. The sensor apparatus of claim 51, wherein the sensor device is
electrically connected between the ends of the wire.
53. The sensor apparatus of claim 51, wherein the second transducer
further comprises a magnetically permeable core around which the
wire is wound.
54. The sensor apparatus of claim 53, wherein the core comprises a
relative magnetic permeability of greater than about 1000.
55. The sensor apparatus of claim 29, wherein the second transducer
comprises a coil of conductive wire whose ends are connected
together.
56. The sensor apparatus of claim 55, wherein the second transducer
further comprises a magnetically permeable core around which the
wire is wound.
57. A sensor apparatus which comprises: a first magnetic transducer
which in use is positioned on a first side of a barrier; and a
second magnetic transducer which in use is positioned on a second
side of the barrier opposite the first side, the second transducer
comprising a magnetic or electrical property which is dependent
upon a sensible condition on the second side of the barrier;
wherein in operation of the sensor apparatus the first transducer
continuously generates a first magnetic field which induces the
second transducer to continuously generate a second magnetic field
that is dependent upon the magnetic or electrical property of the
second transducer; and wherein as the first transducer is
transmitting the first magnetic field it detects the second
magnetic field and in response thereto generates a signal which is
representative of the sensible condition on the second side of the
barrier.
58. The sensor apparatus of claim 57, wherein the first transducer
comprises at least one transmitter coil for generating the first
magnetic field and at least one receiver coil for detecting the
second magnetic field.
59. The sensor apparatus of claim 58, wherein the first transducer
comprises two transmitter coils for generating the first magnetic
field.
60. The sensor apparatus of claim 59, wherein each of the
transmitter coils and the receiver coils comprises a toroid.
61. The sensor apparatus of claim 59, wherein the transmitter coils
are positioned coaxially and in parallel planes and the receiver
coil is positioned parallel to the transmitter coils.
62. The sensor apparatus of claim 61, wherein the receiver coil is
positioned between the transmitter coils a distance sufficient to
substantially null out the first magnetic field at the receiver
coil.
63. The sensor apparatus of claim 61, wherein the receiver coil is
positioned between the transmitter coils a distance sufficient to
substantially null out at the receiver coil a reflected magnetic
field generated by eddy currents in the barrier.
64. The sensor apparatus of claim 57, wherein the first transducer
comprises at least one transmitter coil for generating the first
magnetic field, a first receiver coil for detecting both the second
magnetic field and a reflected magnetic field generated by eddy
currents in the barrier, and a second receiver coil for detecting
primarily the reflected magnetic field.
65. The sensor apparatus of claim 64, wherein the first transducer
comprises two transmitter coils for generating the first magnetic
field.
66. The sensor apparatus of claim 65, wherein the transmitter cons
are positioned coaxially and in parallel planes and the receiver
coils are positioned parallel to the transmitter coils.
67. The sensor apparatus of claim 66, wherein the first receiver
coil is positioned partially between the transmitter coils on one
side of the transmitter coils and the second receiver coil is
positioned partially between the transmitter coils on the
diametrically opposite side of the transmitter coils.
68. The sensor apparatus of claim 67, wherein the second transducer
is positioned opposite the area of overlap between the transmitter
coils and the first receiver coil.
69. The sensor apparatus of claim 64, wherein the first receiver
coil generates a first signal, the second receiver coil generates a
second signal and the sensor apparatus further comprises means for
combining the first and second signals to produce the signal which
is representative of the sensible condition on the second side of
the barrier.
70. The sensor apparatus of claim 58, further comprising a nulling
transducer for generating a third magnetic field which is
sufficient to at least partially null out at the receiver coil a
reflected magnetic field generated by eddy currents in the
barrier.
71. The sensor apparatus of claim 70, wherein the nulling
transducer comprises a coil which is wound around a generally
C-shaped core.
72. The sensor apparatus of claim 71, wherein the C-shaped core is
positioned around a segment of the receiver coil.
73. The sensor apparatus of claim 70, wherein the nulling
transducer comprises a coil which is wound around a toroidal
core.
74. The sensor apparatus of claim 73, wherein the toroidal core is
positioned around a segment of the receiver coil.
75. The sensor apparatus of claim 58, wherein at least one of the
transmitter coil and the receiver coil further comprises a
disc-shaped core which is positioned concentrically therein and is
made of a high permeability material.
76. The sensor apparatus of claim 57, wherein the barrier comprises
a conductive barrier and the first transducer is positioned against
the conductive barrier.
77. The sensor apparatus of claim 57, wherein the barrier comprises
a conductive barrier and the second transducer is positioned
against the conductive barrier.
78. The sensor apparatus of claim 57, wherein the second transducer
comprises a passive sensor device having an electrical property
which is dependent upon the sensible condition on the second side
of the barrier.
79. The sensor apparatus of claim 78, wherein the second transducer
further comprises a coil of conductive wire which is coupled to the
sensor device.
80. The sensor apparatus of claim 79, wherein the sensor device is
electrically connected between the ends of the wire.
81. The sensor apparatus of claim 79, wherein the second transducer
further comprises a magnetically permeable core around which the
wire is wound.
82. The sensor apparatus of claim 81, wherein the core comprises a
relative magnetic permeability of greater than about 1000.
83. The sensor apparatus of claim 57, wherein the second transducer
comprises a coil of conductive wire whose ends are connected
together.
84. The sensor apparatus of claim 83, wherein the second transducer
further comprises a magnetically permeable core around which the
wire is wound.
85. A method for detecting a sensible condition on a first side of
a barrier from a second side of the barrier opposite the first
side, the method comprising: positioning a magnetic transducer on
the first side of the barrier, the transducer comprising a magnetic
or electrical property which is dependent upon a sensible condition
on the first side of the barrier; generating a first magnetic field
on the second side of the barrier to induce the transducer to
generate a second magnetic field which is dependent upon the
magnetic or electrical property of the transducer; detecting the
second magnetic field on the second side of the barrier; and
generating a signal in response to the second magnetic field which
is representative of the sensible condition on the second side of
the barrier.
86. The method of claim 85, wherein the barrier comprises a
conductive barrier.
87. The method of claim 86, further comprising nulling out on the
second side of the barrier a reflected magnetic field generated by
eddy currents in the barrier.
88. The method of claim 85, wherein the steps of generating the
first magnetic field and detecting the second magnetic field are
performed simultaneously.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a sensor apparatus for
sensing a condition inside a barrier, such as a ship hull or an oil
pipeline. In particular, the invention relates to a sensor
apparatus which communicates inductively with a passive sensor
located inside the barrier. The sensor apparatus comprises no
active electrical components inside the barrier and does not
require that external power or data lines penetrate the barrier in
order to power or communicate with the sensor. In addition, the
present invention includes a number of methods for nulling out the
eddy currents which are generated in a conductive barrier during
operation of the sensor apparatus to thereby enable the sensor
apparatus to work effectively through metal or other conductive
barriers.
[0002] Sensors have been used for decades to sense environmental
conditions inside structures. In the hydrocarbon production
industry, for example, sensors are commonly used to sense the
pressure and temperature of the production fluid flowing through
pipelines. Many prior art sensors typically require both a power
source and a data link in order to communicate with an associated
data processing apparatus. Even if the sensor includes its own
power source, such as a battery, a data line is still required to
provide the necessary data link to the sensor. Therefore, the
structure in which the sensor is located must normally be breached
in order to accommodate the data line. However, breaching the
structure for this purpose is undesirable, especially in structures
containing high pressure fluids, such as oil pipelines.
[0003] Although inductive power and data communications systems
exist which can wirelessly transmit both power and data through
many materials, including those typically used to make oil
pipelines, these systems normally require active electrical
components both inside and outside of the structure. However, the
use of active electrical components in certain environments is
problematic. For example, with the exception of certain silicon
carbide electronics, which are usable at temperatures of up to
around 250.degree. C. but are not available for most applications,
even the highest rated Mil-Spec electrical components typically
begin to fail at around 125.degree. C. In this regard, even the
high temperature solders which are used in such components usually
begin to melt at about 220.degree. C. Consequently, in certain
structures, such as subsea oil pipelines, where temperatures can
reach 180.degree. C. to 320.degree. C. or higher, the use of active
electrical components is not practical.
[0004] Furthermore, although inductively interrogated passive
sensor systems exist in the prior art, to the inventors' knowledge
these systems do not work when the passive sensor is positioned
entirely within or against a conductive barrier.
[0005] For example, U.S. Pat. No. 7,159,774 describes an
inductively interrogated passive sensor system in which a passive
magnetic field response sensor is excited by a radio frequency (RF)
signal and in response thereto generates a magnetic field which is
indicative of a condition to be sensed. The passive magnetic field
response sensor comprises either an inductor-capacitor (L-C)
circuit or an inductor-resistor-capacitor (L-R-C) circuit, and the
RF signal is generated by an antenna which is positioned on the
opposite side of a barrier from the sensor. When excited by the RF
signal, the L-C or L-R-C circuit generates a magnetic field which
is dependent on the values of the inductance, capacitance and/or
resistance of its components, which in turn are dependent on the
condition or conditions to which the components are exposed, and
the inductor transmits this magnetic field back to the antenna.
However, this system will not work when the antenna and the entire
passive sensor are positioned on opposite sides of a conductive
barrier. Instead, the inductor must be positioned on the same side
of the barrier as the antenna and connected to the remainder of the
L-C or L-R-C circuit through a hole in the barrier. In addition,
even when positioned outside the conductive barrier, the system
will not work when the inductor is positioned against the barrier
due to the large eddy currents which the magnetic field generates
in the barrier.
SUMMARY OF THE INVENTION
[0006] In accordance with the present invention, these and other
limitations in the prior art are addressed by providing a sensor
apparatus which comprises a first magnetic transducer which in use
is positioned on a first side of a barrier and a second magnetic
transducer which in use is positioned on a second side of the
barrier opposite the first side, the second transducer comprising a
magnetic or electrical property which is dependent upon a sensible
condition on the second side of the barrier. In operation of the
sensor apparatus, the first transducer generates a first magnetic
field which induces the second transducer to generate a second
magnetic field which is dependent upon the magnetic or electrical
property of the second transducer. In addition, the first
transducer detects the second magnetic field and in response
thereto generates a signal which is representative of the sensible
condition on the second side of the barrier.
[0007] In accordance with one embodiment of the invention, the
first transducer comprises at least one transmitter coil for
generating the first magnetic field and at least one receiver coil
for detecting the second magnetic field.
[0008] In accordance with a second embodiment of the invention, the
first transducer comprises two transmitter coils for generating the
first magnetic field. Furthermore, each of the transmitter and the
receiver coils may comprise a toroid.
[0009] In accordance with another embodiment of the invention, the
transmitter coils are positioned coaxially and in parallel planes
and the receiver coil is positioned parallel to the transmitter
coils.
[0010] In accordance with a further embodiment of the invention,
the receiver coil is positioned between the transmitter coils a
distance sufficient to substantially null out the first magnetic
field at the receiver coil.
[0011] In accordance with yet another embodiment of the invention,
the receiver coil is positioned between the transmitter coils a
distance sufficient to at least partially null out at the receiver
coil a reflected magnetic field generated by eddy currents in the
barrier.
[0012] In accordance with still another embodiment of the
invention, the first transducer comprises at least one transmitter
coil for generating the first magnetic field, a first receiver coil
for detecting both the second magnetic field and a reflected
magnetic field generated by eddy currents in the barrier, and a
second receiver coil for detecting primarily the reflected magnetic
field. In this embodiment, the first transducer may comprise two
transmitter coils for generating the first magnetic field. In
addition, the transmitter coils may be positioned coaxially and in
parallel planes and the receiver coils may be positioned parallel
to the transmitter coils. Furthermore, the first receiver coil may
be positioned partially between the transmitter coils on one side
of the transmitter coils, the second receiver coil may be
positioned partially between the transmitter coils on the
diametrically opposite side of the transmitter coils, and the
sensor transducer may be positioned opposite the area of overlap
between the transmitter coils and the first receiver coil. In
operation of this embodiment of the invention, the first receiver
coil generates a first signal, the second receiver coil generates a
second signal and the sensor apparatus further comprises means for
combining the first and second signals to produce a signal which is
representative of the sensible condition on the second side of the
barrier.
[0013] In yet another embodiment of the invention, the sensor
apparatus comprises a nulling transducer for generating a third
magnetic field which is sufficient to at least partially null out
at the receiver coil a reflected magnetic field generated by eddy
currents in the barrier. The nulling transducer may comprise, for
example, a coil which is wound around a toroidal or a generally
C-shaped core which is positioned around a segment of the receiver
coil.
[0014] In accordance with another embodiment of the invention, at
least one of the transmitter coil and the receiver coil may further
comprise a disc-shaped core which is positioned concentrically
therein and is made of a high permeability material.
[0015] In accordance with yet another embodiment of the invention,
the second transducer comprises a magnetically permeable member
having a magnetic property which is dependent upon the sensible
condition on the second side of the barrier. In this embodiment,
the member may comprise a relative magnetic permeability of greater
than about 1000.
[0016] In accordance with still another embodiment of the
invention, the second transducer comprises a passive sensor device
having an electrical property which is dependent upon the sensible
condition on the second side of the barrier. The second transducer
may also comprise a coil of conductive wire which is coupled to the
sensor device. For example, the sensor device may be connected
between the ends of the wire. The sensor transducer may further
comprise a magnetically permeable core around which the wire is
wound. The core may comprise a relative magnetic permeability of
greater than about 1000.
[0017] Thus, the sensor apparatus of the present invention provides
a simple but effective means for sensing conditions in a part of a
structure or barrier which is difficult or impractical to access,
such as in an oil pipeline. This is accomplished by installing the
active electrical components of the sensor apparatus, i.e., the
first transducer and any associated signal processing equipment,
outside the barrier and only installing the second transducer and
the sensor inside the barrier. Moreover, since the second
transducer and the sensor are non-powered devices and the second
transducer communicates with the first transducer through magnetic
induction, the sensor apparatus does not require the barrier to be
penetrated with external power or data lines.
[0018] Another advantage of the present invention is that, since
the second transducer and the sensor are non-powered devices and
the active electrical components are located outside the barrier,
the sensor apparatus of the present invention is particularly
suitable for use in high pressure, high temperature and explosive
environments.
[0019] Furthermore, since the sensor apparatus of the present
invention effectively nulls out the eddy current-generated magnetic
field at the receiver coil, the sensor apparatus is particularly
effective for use in sensing conditions inside a conductive
barrier. Moreover, this feature allows the sensor apparatus to work
even when the transmitter coils are positioned near or against the
conductive barrier, such as when the first transducer is mounted
directly on the outer surface of the conductive barrier.
[0020] These and other objects and advantages of the present
invention will be made apparent from the following detailed
description, with reference to the accompanying drawings. In the
drawings, the same reference numbers may be used to denote similar
components in the various embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a block diagram of one embodiment of the sensor
apparatus of the present invention;
[0022] FIG. 2 is a perspective view of the interrogator and sensor
transducer components in accordance with one embodiment of the
present invention;
[0023] FIG. 2A is a perspective view of the interrogator transducer
components in accordance with another embodiment of the present
invention;
[0024] FIG. 3A is a perspective view of one embodiment of the
sensor transducer component of the present invention;
[0025] FIG. 3B is a perspective view of a second embodiment of the
sensor transducer component of the present invention;
[0026] FIG. 3C is a perspective view of a third embodiment of the
sensor transducer component of the present invention;
[0027] FIG. 3D is a perspective view of a fourth embodiment of the
sensor transducer component of the present invention;
[0028] FIG. 4 is a plot of the representative magnetic fields
generated by the sensor apparatus of the present invention;
[0029] FIG. 5 is a plot similar to FIG. 4 but showing the magnetic
fields after one of the nulling techniques of the present invention
has been applied to the interrogator transducer;
[0030] FIG. 6 is a plot of the Mean Squared Error between the
magnetic field detected by the interrogator transducer through a
conductive barrier and the actual magnetic field generated by the
sensor transducer after one of the nulling techniques of the
present invention has been applied to the interrogator
transducer;
[0031] FIG. 7 is a plot similar to FIG. 6 but without the nulling
technique applied to the interrogator transducer;
[0032] FIG. 8 is a perspective view of the interrogator transducer
and sensor transducer components of another embodiment of the
present invention; and
[0033] FIG. 9 is a perspective view of the interrogator transducer
and sensor transducer components of still another embodiment of the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] A block diagram of an illustrative embodiment of the sensor
apparatus of the present invention is shown in FIG. 1. The sensor
apparatus of this embodiment, which is indicated generally by
reference number 10, comprises a magnetic interrogator transducer
12 which in use is positioned on one side of a barrier 14, and a
magnetic sensor transducer 16 which in use is positioned on the
opposite side of the barrier and is magnetically coupled to the
interrogator transducer. In this embodiment of the invention, a
preferably very low frequency (VLF) AC signal from a signal
generator 18 is applied to the interrogator transducer 12, which in
response thereto generates a time-varying magnetic field that
propagates back through the barrier 14 and is impressed on the
sensor transducer 16.
[0035] As will be described more fully below, the magnetic field
generated by the interrogator transducer 12 induces the sensor
transducer 16 to generate its own time-varying magnetic field. This
magnetic field is dependent upon the magnetic or electrical
properties of the sensor transducer 16, which in turn are dependent
upon the sensible condition to which the sensor transducer is
exposed on its side of the barrier 14. In the context of the
present invention, a sensible condition can be any condition which
is capable of being sensed, such as pressure, temperature,
proximity to other objects, orientation and fluid level.
[0036] Thus, the magnetic field generated by the sensor transducer
16 contains information representative of the condition which is
sensed by the sensor transducer. This magnetic field is transmitted
through the barrier 14 and is detected by the interrogator
transducer 12. The resulting data signal produced by the
interrogator transducer 12 is fed to a signal processor 20, which
extracts the information relating to the sensible condition and
transmits this information to, for example, a display unit 22.
[0037] The sensor apparatus 10 may comprise any suitable signal
generator 18 and signal processor 20. For example, a working
embodiment of the invention was constructed using an Agilent 3220A
function generator as the signal generator 18. The signal from this
signal generator was amplified by a Crown analog amplifier prior to
being transmitted to the interrogator 12. The return signal from
the interrogator transducer 12 was fed to a National Instruments
PXI signal processor 20, which comprised a NI PXI-1050 chassis, a
NI PXI-8187 controller and a NI PXI-6251 analog input. Other signal
generators 18 and signal processors 20 which are suitable for use
in the present invention will be readily apparent to persons of
ordinary skill in the art.
[0038] In one embodiment of the invention, the interrogator
transducer 12 is operated to generate a magnetic field continuously
over a period of time. This continuous magnetic field will in turn
induce the sensor transducer 16 to generate a continuous magnetic
field during this same period of time. Thus, the interrogator
transducer 12 will be transmitting its magnetic field at the same
time it is detecting the magnetic field generated by the sensor
transducer 16. By operating in this manner, the sensor transducer
16 is able to provide near real-time information regarding the
sensible condition to which it is exposed.
[0039] Referring to FIG. 2, the interrogator transducer 12 in
accordance with one embodiment of the invention includes two
transmitter coils 24 which are connected to the signal generator 18
and a receiver coil 26 which is connected to the signal processor
20. In this embodiment of the invention, each of the transmitter
and receiver coils 24, 26 comprises a conductive wire 28 which is
wrapped around a doughnut-shaped core 30. The two transmitter coils
24 are positioned coaxially and in parallel planes, and the
receiver coil 26 is positioned parallel to and preferably partially
between the transmitter coils. As will be explained in more detail
below, the distance which the receiver coil 26 is inserted between
the transmitter coils 24 is selected so that the magnetic field
generated by the transmitter coils is nulled out at the receiver
coil.
[0040] In an alternative embodiment of the invention shown in FIG.
2A, each of the transmitter coils 24 and/or the receiver coil 26
also comprises a high permeability disc-shaped core 32 (shown in
phantom in FIG. 2) which is positioned within the doughnut-shaped
core 30. Such an arrangement increases the magnetic coupling
between the interrogator transducer 12 and the sensor transducer 16
and therefore increases the strength of the transmitted and
received signals.
[0041] In an exemplary embodiment of the invention, each
transmitter coil 24 is a toroid comprising 36 turns of 22 AWG
magnet wire (i.e., varnish coated solid wire) around a core 30
having a thickness of 0.1875 inch, an outer diameter of 7.25 inches
and an inner diameter of 4.60 inches. The two transmitter coils 24
are electrically connected in parallel and are positioned so that
for a given input their respective magnetic fields are oriented in
the same direction, for example in the manner of a Helmholtz coil.
Also, the receiver coil 26 is a toroid comprising 600 turns of 34
AWG magnet wire around a core 30 having a thickness of 0.1875 inch,
an outer diameter of 7.25 inches and an inner diameter of 4.60
inches. If employed in this exemplary embodiment of the invention,
each high permeability disc-shaped core 32 would comprise a
thickness of about 0.17 inches and a diameter of about 4.5 inches
and would be retained in position within the cores 30 by a suitable
non-conducting structure.
[0042] In use of the sensor apparatus 10, the interrogator
transducer 12 is positioned on one side of the barrier 14 and the
sensor transducer 16 is positioned on the opposite side of the
barrier (which in FIG. 2 is illustrated as being transparent for
purposes of clarity). The barrier 14 may comprise any conductive or
nonconductive material or substance which is disposed between the
interrogator and sensor transducers 12, 16. Examples of conductive
materials or substances include metal, saltwater and even animal
tissue.
[0043] An example of a metal barrier is a pressure-containing metal
pipe which is used in the hydrocarbon production industry to convey
production fluid from a well to a production or storage facility.
In this example, the interrogator transducer 12 would be located on
the outside of the pipe and the sensor transducer 16 would be
positioned on the inside of the pipe 14 to measure a condition of
the production fluid, such as its pressure or temperature. An
example of a saltwater barrier is seawater. In this example, the
sensor transducer 16 would be mounted on a subsea component, such
as a pipeline, to measure a condition of the component and the
interrogator transducer 12 would be positioned in proximity to, but
not necessarily in contact with, the sensor transducer. An example
of an animal tissue barrier is human tissue. In this example, the
interrogator transducer 12 would be located outside the body and
the sensor transducer 16 would be placed in the body, for example
under the skin, to measure a condition of the body, such as
arterial pressure or intracranial pressure.
[0044] Examples of nonconductive materials or substances which may
constitute barriers for purposes of the present invention include
plastics, elastomers and various insulation materials. An example
of a plastic barrier is a plastic waterproof housing for a sensor
transducer 16. In this example, the sensor transducer 16 would be
positioned in a plastic housing which is mounted to, e.g., a subsea
component and the interrogator transducer 12 would be positioned
against or in proximity to the housing. An example of an insulation
barrier is a layer of epoxy or polymer resin which is applied to,
e.g., a subsea component. In this example, the sensor transducer 16
would be mounted on the subsea component under the insulation layer
and the interrogator transducer 12 would be located on the outside
of the insulation layer.
[0045] The barrier 14 may also comprise a combination of two or
more materials or substances For example, the barrier 14 may
comprise a non-conductive housing which is submerged in saltwater.
In this example, the sensor transducer 16 would be positioned in
the housing and the interrogator transducer 12 would be positioned
in the seawater in proximity to, but not necessarily in contact
with, the housing. In any of the above examples, the interrogator
and sensor transducers 12, 16 may be positioned either in contact
with or spaced-apart from the barrier 14.
[0046] In accordance with the present invention, the sensor
transducer 16 is a non-powered device. In the context of the
present invention, a non-powered device is a device to which no
external power is supplied (except for the magnetic flux from the
interrogator transducer, which will cause some current to flow
through the device). In addition, the sensor transducer 16
communicates with the interrogator transducer 12 through magnetic
induction. Therefore, the sensor apparatus 10 does not require the
sensor transducer 16 to be connected to external power or data
lines. Consequently, no need exists to penetrate the barrier 14 in
order to accommodate such lines.
[0047] Referring to FIG. 3A, one embodiment of the sensor
transducer 16 of the present invention comprises a conductive wire
34 which is wound concentrically around a disc-shaped core 36 and
is connected to a passive sensor device 38. In the context of the
present invention, a passive sensor device is a sensor device which
does not require any power, except for the power generated by the
induced magnetic flux, in order to alter the return magnetic signal
in response to changes in the sensible conditions. The core 36 is
made of a material which ideally comprises a relative magnetic
permeability of greater than about 1000. In an exemplary embodiment
of the invention, the wire 34 comprises 19 turns of 22 AWG magnet
wire and the core 36 is made of 3C90 Ferrite and has a diameter of
2.20 inches and a thickness of 0.725 inch. In this embodiment, the
sensor transducer 16 is ideally positioned so that the core 36 is
parallel to the transmitter and receiver coils 24, 26.
[0048] In an alternative embodiment of the sensor transducer 16
which is shown in FIG. 3B, the high magnetic permeability core 36
is omitted and the sensor transducer merely comprises the wire 34
and the passive sensor device 38. In this embodiment, the wire 34
may comprise 120 turns of 34 AWG magnet wire wound to a diameter of
3.0 inches. In the embodiments of the sensor transducer 16 shown in
FIGS. 3A and 3B, the passive sensor device 38 is electrically
connected between the ends of the wire 34. However, the sensor
device 38 may alternatively be magnetically coupled to the wire 34
or to the core 36. The principles of the present invention hold for
either case.
[0049] The sensor device 38 may comprise any passive sensor whose
electrical property, such as resistance, inductance or capacitance,
changes in response to changes in the sensible condition to which
the sensor is subjected. Examples of passive sensors include
thermistors, which change resistance in response to changes in
temperature; strain gauges, which change resistance in response to
changes in strain; and capacitive and crystal-based pressure
sensors, which change capacitance in response to changes in
pressure. In addition, many active flow meters, fluid level
sensors, position sensors and orientation sensors change resistance
or capacitance with changes in their corresponding measured
quantities. As such, these commercially available off-the-shelf
devices may be used in conjunction with the present invention
without their corresponding power and data links.
[0050] In operation of the sensor apparatus 10, the transmitter
coils 24 are driven with a preferably VLF AC signal having a
particular frequency or frequencies. In response to this signal,
the transmitter coils 24 generate a magnetic flux at the same
frequency or frequencies as the AC signal. Some of this flux passes
through the barrier 14 and also through the core 36 of the sensor
transducer 16. The flux passing through the core 36 induces a small
current to flow through the wire 34. The current flowing through
the wire 34 in turn generates a magnetic field that, passes back
through the barrier 14 and is detected by the receiver coil 26. In
the case of the sensor transducer 16 shown in FIG. 3B, which does
not include a core 36, the magnetic flux generated by the
transmitter coils 24 passes through the region defined by the wire
34 and induces a small current to flow through the wire which in
turn generates a magnetic field that passes back through the
barrier and is detected by the receiver coil 26.
[0051] As will be appreciated by persons of ordinary skill in the
art, the amplitude, phase, resonant frequency and bandwidth of the
current flowing through the wire 34 are dependent upon the
electrical properties of the passive sensor device 38 connected to
the wire. Thus, a change in the resistance of the sensor device 38
will result in changes in the amplitude, phase and bandwidth of the
current, while a change in the capacitance or inductance of the
sensor will result in changes in the amplitude, phase, bandwidth
and resonant frequency of the current. In addition, these changes
will induce corresponding changes in the amplitude, phase, resonant
frequency and bandwidth of the magnetic field generated by the
current. Thus, the changes in the amplitude, phase, resonant
frequency and bandwidth of the magnetic field generated by the
current flowing through the wire 34 are related to the change in
the electrical property of the sensor device 38, which in turn is
related to the change in the sensible condition to which the sensor
is subjected.
[0052] As mentioned above, the magnetic field generated by the
current flowing though the wire 34 is detected by the receiver coil
26. In response to this magnetic field, the receiver coil 26
generates a data signal in the form of an AC current which has the
same amplitude, phase, resonant frequency and bandwidth as the
magnetic field. The data signal is transmitted to the signal
processor 20, which amplifies the signal and, using an appropriate
known measuring circuit, measures the amplitude, phase, resonant
frequency or bandwidth of the signal. For example, the signal
processor 20 may comprise a digital signal processor integrated
circuit running a known phase detection algorithm for measuring the
phase of the signal.
[0053] The measured values of the amplitude, phase, resonant
frequency or bandwidth of the data signal are correlated with the
conventional measurement values of the sensible condition using a
suitable calibration procedure. If the passive sensor device 38 is
a thermistor, for example, the measured values of amplitude, phase,
resonant frequency or bandwidth of the data signal are correlated
with the corresponding temperatures of the environment in which the
sensor is located. A number of known calibration procedures may be
used for this purpose.
[0054] Another embodiment of the sensor transducer 16 is shown in
FIG. 3C. In this embodiment of the invention, the sensor device 38
is omitted and the sensor transducer 16 merely comprises a core 36
wound with a wire 34, the ends of which are joined together. As is
readily understood by those of ordinary skill in the art, the
magnetic permeability of the core 36 and the electrical resistivity
of the wire 34 will change with changes in certain sensible
conditions to which the sensor transducer 16 is exposed. For
example, both of these parameters will change in response to
changes in temperature. In addition, the magnetic permeability of
the core 36 will change in response to changes in hydrostatic
pressure. The changes in permeability and resistivity will in turn
alter the amplitude and phase of the magnetic field produced by the
sensor transducer 16 in response to the time-varying magnetic field
generated by the interrogator transducer 12, and these changes in
amplitude or phase can be detected by the interrogator transducer
to provide an indication of the sensible conditions of the
environment in which the sensor transducer 16 is located.
[0055] A further embodiment of the sensor transducer 16 is shown in
FIG. 3D. In this embodiment the sensor transducer 16 simply
comprises a coil of wire 34 whose ends are joined together. As in
the previously embodiment, changes in, for example, the temperature
to which the sensor transducer 16 is exposed will change the
resistivity of the wire 34 and consequently alter the magnetic
field produced by the sensor transducer in response to the magnetic
field generated by the interrogator transducer 12. These changes in
the magnetic field can then be detected by the interrogator
transducer 12 to provide an indication of the sensible conditions
of the environment in which the sensor transducer 16 is
located.
[0056] As mentioned above, the receiver coil 26 is ideally
positioned at least partially between the transmitter coils 24. The
purpose of this is to null out the magnetic field which the
receiver coil 26 sees from the transmitter coils 24. Accordingly,
the distance which the receiver coil 26 is positioned between the
transmitter coils 24 is selected so that equal amounts of flux pass
through the receiver coil in both the positive and negative
directions, thereby resulting in the magnetic field generated by
the transmitter coils being substantially zero at the receiver
coil. This distance may be determined empirically during the design
of the sensor apparatus 10 and may be maintained using any suitable
housing or supporting structure in which the coils 24, 26 are
disposed.
[0057] The geometric nulling technique just described is desirable
to facilitate the detection by the receiver coil 26 of the magnetic
field generated by the sensor transducer 16. Since the magnetic
field generated by the sensor transducer 16 is small in comparison
to that generated by the transmitter coils 24, the receiver coil 26
may otherwise not be able to distinguish the magnetic field
generated by the sensor transducer from that generated by the
transmitter coils. Of course, other techniques, including
non-mechanical signal processing techniques, may be used instead to
facilitate the detection by the receiver coil 26 of the magnetic
field generated by the sensor transducer 16.
[0058] When the sensor apparatus 10 is used in conjunction with a
barrier 14 comprising a conductive medium, such as a large body of
metal, the eddy currents developed in the barrier as a result of
the magnetic field generated by the transmitter coils 24 create a
relatively large reflected magnetic field. As a result, the
magnetic field detected by the receiver coil 26 will be an
arithmetic sum of the magnetic field from the sensor transducer 16
and the reflected magnetic field from the barrier 14. As such, the
effective signal to noise ratio is decreased and the ability to
make high resolution sensor measurements is compromised. The
amplitude of the magnetic field generated by the eddy currents
increases, and the effective signal to noise ratio decreases, the
closer the transmitter coils 24 are positioned to the conductive
barrier. Consequently, the resulting low signal to noise ratio may
reduce the effectiveness of the sensor apparatus 10 when the
transmitter coils 24 are positioned near or against the conductive
barrier.
[0059] In accordance with the present invention, the noise
attributable to the eddy current-induced magnetic field from the
conductive barrier 14 may be minimized or eliminated by, in effect,
nulling out this magnetic field, thereby enabling the transmitter
coils 24 to be positioned near or adjacent the conductive barrier.
In the embodiment of the invention shown in FIG. 2, for example,
the eddy current-induced magnetic field may be reduced by adjusting
receiver/transmitter interleave distance, i.e., the distance the
receiver coil 26 is inserted between the transmitter coils 24.
[0060] The magnetic field detected by the receiver coil 26 is the
arithmetic sum of primarily three fields: the field generated by
the transmitter coils 24 (which may be referred to as the
transmitter field), the field generated by the eddy currents in the
barrier 14 (which may be referred to as the eddy current field),
and the field generated by the sensor transducer 16 (which may be
referred to as the sensor field). (A fourth field is produced by
the eddy currents induced in the barrier 14 by the magnetic field
generated by the sensor transducer 16, but this field is typically
very small in comparison to the transmitter, the eddy current and
the sensor fields and can therefore usually be ignored, although it
may be nulled out at the receiver coil using the nulling techniques
described herein if desired.) The transmitter, eddy current and
sensor fields will have the same frequency as the excitation signal
from the signal generator 18 but separate amplitudes and phases.
The eddy current field will typically have a considerably higher
amplitude than that of the sensor field, which is the field we wish
to detect. The relationship between the transmitter field, the eddy
current field and the sensor field is shown by way of example in
FIG. 4.
[0061] As seen from the receiver coil 26, the amplitude of the
transmitter field can be increased or decreased by changing the
receiver/transmitter interleave distance. As described above, this
mechanism is used to null out the transmitter field at the receiver
coil 26 so that the sensor field can be more easily detected.
However, since the eddy current field is out of phase with the
transmitter and sensor fields, further adjustment of the
receiver/transmitter interleave distance can allow for partial or
total cancelation of the eddy current effect by summing these
out-of-phase fields.
[0062] By way of illustration, FIG. 5 shows that with a nulled
transmitter field (which is achieved by adjusting the
receiver/transmitter interleave distance), the field detected by
the receiver coil 26 is dominated by the eddy current field.
However, by further adjusting the amplitude of the transmitter
field as seen by the receiver coil 26 (by further adjusting the
receiver/transmitter interleave distance), the transmitter field
can be made to partially or fully cancel out the out-of-phase eddy
current field, which will result in the cumulative field detected
by the receiver coil being more closely matched to the sensor
field.
[0063] FIG. 6 is a plot of the Mean Squared Error (MSE) between the
field detected by the receiver coil 26 and the actual sensor field
as a function of the sensor and eddy current field phases with the
above-described nulling technique being employed. The MSE shown is
for an optimal receiver/transmitter interleave distance, which is
different for each phase combination. As can be seen in FIG. 6, for
eddy current field phases near 0.degree. and near 180.degree., the
MSE is quite low for any range of sensor field phase, as the
magnitude of the transmitter field seen by the receiver coil 26 can
be used to cancel out most or all of the eddy current field. In
comparison, FIG. 7 shows the received field mean squared error
without this nulling technique. As can be seen, even though a
complete nulling for any arbitrary eddy current field phase (which
depends on conductivity of the barrier 14) may not be achieved, the
results are much improved with even this simplest of nulling
techniques. For many highly conductive materials, the eddy current
field will have a phase near 180.degree.. Thus, this nulling
technique is particularly well suited to nulling out the eddy
currents from these materials.
[0064] In accordance with the present invention, other techniques
may be used to null out the eddy current field. Referring to FIG.
8, for example, the sensor apparatus 10 may be provided with a
second receiver coil 26' on the other side of the transmitter coils
24. In use, the interrogator transducer 12 is positioned so that
the area of overlap between the transmitter coils 24 and the first
receiver coil 26 is opposite the sensor transducer 16. Because the
area of sensitivity to the sensor field is primarily in this area
of overlap, the first receiver coil 26 will primarily detect both
the sensor field and the eddy current field, while the second
receiver coil 26' will primarily detect only the eddy current
field. By subtracting these signals using, e.g., a differential
amplifier, the remaining signal would represent the magnetic field
generated by the sensor transducer 16 alone.
[0065] Another technique for nulling out the eddy current field is
illustrated in FIG. 9. In this embodiment, the sensor apparatus 10
includes a nulling transducer 42 for generating a magnetic field
which nulls out the eddy current field seen by the receiver coil
26. The nulling transducer 42 comprises coil which is wound on a
toroidal or, as shown in FIG. 9, a generally C-shaped core that is
positioned around a segment of the receiver coil 26. The coil is
driven with a signal which is initially 180 degrees out of phase
with the excitation signal used to drive the transmitter coils 24.
During calibration of this apparatus, the signal phase and
amplitude are adjusted until the eddy current field as seen by the
receiver coil 26 is essentially zero. Thus, during operation of
this embodiment of the sensor transducer, the only field detected
by the receiver coil 26 will be the sensor field.
[0066] One advantage of the present invention is that, since the
sensor transducer 16 is a non-powered device and the active
electrical components of the sensor apparatus 10 (i.e., the
interrogator transducer 12, the signal generator 18 and the signal
processor 20) are located outside the barrier, the sensor apparatus
is particularly suitable for use in high pressure, high temperature
and explosive environments. In an embodiment of the invention which
is suitable for measuring temperature under such conditions, the
wire 34 ideally comprises high temperature varnished copper wire,
the core 36 is preferably made of steel or another high
permeability material with a high Curie temperature, and the sensor
device 38 is a conventional high temperature thermistor.
[0067] It should be recognized that, while the present invention
has been described in relation to the preferred embodiments
thereof, those skilled in the art may develop a wide variation of
structural and operational details without departing from the
principles of the invention. Therefore, the appended claims are to
be construed to cover all equivalents falling within the true scope
and spirit of the invention.
* * * * *